FRIT DEVELOPMENT FOR SLUDGE BATCH 6 Page: 4 of 52
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The Savannah River National Laboratory (SRNL) evaluated a large number of Sludge Batch 6
(SB6) composition projections to support frit optimization for SB6 vitrification at the Defense
Waste Processing Facility (DWPF). The evaluations discussed in this report occurred over a
period of about 4 months, and included about 40 composition projections, developed by both
Savannah River Remediation (SRR) and SRNL. Paper study assessments were used to evaluate
the sludge composition projections with arrays of potential frit compositions using the predictive
models in the DWPF Product Composition Control System (PCCS). Both nominal sludge
compositions and sludge compositions with anticipated compositional variation were considered.
The model predictions were used to identify candidate frit compositions for each SB6 projection
and to provide some guidance to SRR on washing and blending strategies for SB6 preparation.
This report presents a chronological review of this process and summarizes the findings at each
Following initial feedback from this work, the number of washes in Tank 51 was reduced to
increase the projected sodium concentration in SB6. Analyses of predicted frit performance
before and after a potential decant of Tank 40 showed that the post-decant SB6 composition
would be difficult to process with any frit composition and that this scenario should be avoided.
Based on the most recent SB6 projections (February 2010 SB6 composition projections
developed at SRNL using the measured SB6 qualification sample composition and the revised
Tank Farm washing plan), Frit 418 appears to be viable for SB6 processing at a target waste
loading of 36%. A Nominal Stage PCCS Measurement Acceptability Region (MAR) assessment
gave projected operating windows of 25-41% waste loading, limited by predictions of nepheline
crystallization. The projected operating window is reduced to 25-38% waste loading when
anticipated compositional variation is considered, again limited by predictions of nepheline
crystallization. Blend points between 62 and 40 inches of Sludge Batch 5 (SB5) heel in Tank 40
had no practical impact on the projected performance of Frit 418. This assessment is made from
a paper study approach only and assumes that no decant of Tank 40 will occur during SB6
processing. A decant of Tank 40 would reduce the Na2O concentration in Tank 40 to a point
where it would be very difficult to target a waste loading of 36% for SB6 with Frit 418.
The performance of Frit 418 with SB6 is limited by predictions of nepheline crystallization,
which is a durability limiting constraint. Alternatives to Frit 418 are available that can provide
equivalent projected operating windows and are limited by process related constraints (i.e.,
liquidus temperature predictions) rather than durability limiting constraints. A separate
memorandum has recently been issued that discusses the use of Frit 418 for SB6 vitrification.i
Potential differences in melt rate among these alternative frits will be discussed in a forthcoming
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Fox, K.; Edwards, T. & Zamecnik, J. FRIT DEVELOPMENT FOR SLUDGE BATCH 6, report, May 13, 2010; South Carolina. (https://digital.library.unt.edu/ark:/67531/metadc931911/m1/4/: accessed April 19, 2019), University of North Texas Libraries, Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.